Brake piston

ABSTRACT

A brake piston includes a piston pocket. The piston pocket receives a nut that is axially moveable along a center axis. The nut is restricted from rotating within the piston pocket when a torque due to a frictional engagement between a nut seal and an inner pocket wall, one or more projections, or both is greater than an it torque at the nut. The nut is rotatable within the piston pocket when a torque due to the frictional engagement between the nut seal and the inner pocket wall, the one or more projections or both is less than the input torque at the nut and is less than the torque due to the frictional engagement between the piston and the piston seal.

This disclosure claims the benefit of U.S. Provisional PatentApplication No. 62/263,198 filed on Dec. 4, 2015 the disclosure of whichis hereby incorporated by reference herein in its entirety for allpurposes.

FIELD

These teachings relate generally to a brake piston, and moreparticularly to a brake piston and linkage for moving the brake pistonduring a parking brake apply and during release of the parking brake.

BACKGROUND

A brake system may be used to decelerate or restrict movement of avehicle. A disc brake system is a common type of brake system. During astandard brake apply in a disc brake system, fluid is pressurized, whichcauses one or more brake pistons to move one or more brake pads againsta brake rotor to create a clamping force. The clamping force mayfunction to decelerate or restrict movement of the vehicle. To releasethe brake apply and/or release the clamping force, the fluid isdepressurized and, accordingly, the one or more brake pistons and brakepads move away from the brake rotor. Once released, the vehicle is freeto move again.

A parking brake system may utilize one or more components of the brakesystem to maintain a vehicle in a stopped or parked position. In modernapplications, the parking brake system may be an electromechanicalsystem. An exemplary electromechanical parking brake system includes oneor more motor gear units and one or more linkages. A linkage maycomprise a spindle and a nut. The nut may be keyed to an inner portionof a brake piston (i.e., to a piston pocket) so that the nut and thebrake piston are restricted from independently rotating relative to oneanother.

During a parking brake apply in an exemplary electromechanical parkingbrake system, the motor gear unit may rotate the spindle in a firstdirection, which may cause the nut to translate axially and push thecorresponding brake piston towards and eventually into contact with oneof the brake pads to develop the clamping force to maintain the vehiclein a stopped or parked position. To release the parking brake and/or theclamping force, the motor gear unit may rotate the spindle in anopposite direction so that the nut and the corresponding brake pistonmove away from the brake pad so that the brake pads can move away fromthe brake rotor so that the vehicle is free to move again.

While the aforementioned parking brake system has proven satisfactory,opportunities for improvement may exist. For example, because the nut iskeyed to the inner portion of the brake piston, properly aligning thenut with the brake piston during assembly can be time-consuming andcumbersome. Also, for example, during release of the parking brake, oncethe nut can no longer axially move (i.e., once the nut and the spindlethread stop make contact), further rotation of the spindle by the motorgear unit may undesirably cause the nut to rotate the brake piston,which may tear or otherwise damage the piston boot That surrounds thebrake piston. Moreover, for example, damage may occur to the motor gearunit, the linkage, or both if the motor gear unit continues to rotatethe spindle, but the nut is restricted from axially moving.

Accordingly, it may be desirable to have an improved parking brakesystem, an improved brake piston, an improved linkage, or a combinationthereof. It would be attractive to have a nut that is not keyed to aninner portion or pocket of the brake piston, but can still be used todevelop the clamping force necessary to maintain a vehicle in a stoppedor parked position. It may be desirable to have a spindle and a nut thatcan be quickly and easily assembled together. It may be attractive tohave a nut that is not keyed to an inner portion of the brake piston sothat assembly time of the nut and the brake piston can be improved. Itmay be attractive to have a nut that is not keyed to an inner portion ofthe brake piston but is still restricted from rotating within the innerportion of the brake piston during a parking brake apply and/or duringrelease of the parking brake. It may also be attractive to have a nutthat can be restricted from rotating within the inner portion of brakepiston when there is no clamping force or while the clamping force isbeing created, but allowed to rotate therein once the frictionalengagement between the spindle and the nut is greater than thefrictional engagement between the nut and the piston pocket, or,preferably, between a nut seal and an inner pocket wall.

SUMMARY

The present teachings provide an improved brake system, at improvedparking brake system, or both. More specifically, the present teachingsprovide improved components for a brake system, a parking brake system,or both. Even more specifically, provided is an improved brake pistonand an improved linkage for a brake system, a parking brake system, orboth.

The brake piston can be used during standard braking to decelerate orrestrict movement of a vehicle. The brake piston can also be used duringa parking brake apply to maintain the vehicle in a stopped or parkedposition. The brake piston includes a piston pocket. The piston pocketincludes an inner pocket wall. The inner pocket wall may besubstantially smooth. Alternatively, the inner pocket wall may includeone or more projections or, preferably, two or more projections, whichmay extend longitudinally from an opening to the piston pocket to abottom pocket surface. The linkage is comprised of a nut and a spindle.The nut includes a nut seal that frictionally engages the substantiallysmooth inner pocket wall, the protections, or both.

During a parking brake apply, the nut can be axially moved toward abottom pocket surface without rotating. During release of the parkingbrake, the nut can be axially moved away from the bottom pocket surfacewithout rotating. When little or no clamping force exists (i.e., duringthe initial creation of the parking brake apply and/or during release ofthe parking brake) the motor gear unit rotates the spindle, which causesthe nut to move axially without rotating. The nut may be restricted fromrotating due to the torque or frictional engagement between the nut sealand the inner pocket wall, the nut seal and the one or more projections,or both being greater than the torque acting on the nut from thespindle.

During a parking brake apply, rotation of the spindle in an applydirection may cause the nut to move axially in an apply direction untilthe nut contacts the bottom pocket surface. After contact between thenut and the bottom pocket surface is made, further rotation of thespindle causes the nut to move or push the brake piston, which in turnmoves or pushes the brake pads towards the brake rotor. The motor gearunit continues rotating the spindle so that the brake piston and thebrake pads are moved or pushed against the brake rotor until a desiredclamping force is developed to park the vehicle. During release of theparking brake, the torque from the frictional engagement between the nutseal and the inner pocket surface, the projections, or both may begreater than the torque of the spindle and the nut. Accordingly,rotation of the spindle in the release direction causes the nut to moveaxially in the release direction, rather than the nut rotating.Continued rotation of the spindle in the release direction causes thenut to move axially away from the (now) stationary brake piston untilthe clamping force is fully released.

There may be a condition, however, where the nut rotates in the pistonpocket. This condition may occur when the nut or an abutment of the nutcontacts the spindle thread stop. This contact may occur when worn brakepads are to be replaced with new brake pads, and/or when the brakecaliper is to be removed from the knuckle or support of a vehicle.Contact between the nut and the spindle thread stop may occur when thespindle is rotated in a release direction and the nut is moved away fromthe piston pocket bottom surface until the nut contacts the spindlethread stop. If the nut or the nut abutment contacts the spindle threadstop, and the motor gear unit continues to rotate the spindle, thetorque due to frictional engagement between the nut seal and the pistonpocket may be less than the torque of the motor gear unit, the spindle,and the nut. Accordingly, during this condition, the nut may rotatewithin the piston pocket. Because the torque due to the frictionalengagement between the outer surface of the brake piston and the pistonboot surrounding the brake piston may be greater than the torque due tothe frictional engagement between the motor gear unit, the spindle, andthe nut, if the nut were not allowed to rotate in the piston pocket, thebrake piston would try to rotate in the piston boot, which may causedamage to the piston boot. Thus, by the nut rotating in the pistonpocket during this condition when the nut contacts the spindle threadstop, damage to the brake piston can be prevented.

The present teachings also provide a brake piston that comprises apiston pocket. A nut is received in the piston pocket. The nut accordingto the teachings herein is axially moveable along a center axis of thebrake piston. The nut according to the teachings herein is not keyed tothe piston pocket. This means that the nut can be quickly and easilyinstalled in the piston pocket without requiring the nut to berotationally aligned relative to the piston pocket before installing thenut as may be the case in designs where the nut is keyed to a specificrotational position of the piston pocket. The nut includes a nut sealthat frictionally engages the piston pocket so that the nut isrestricted from rotating within the piston pocket during a parking brakeapply and during release of the parking brake. However, the nut may berotatable within the piston pocket during a condition where a nutabutment contacts the spindle thread stop and the spindle continues tobe rotated.

The present teachings also provide a disc brake system comprising abrake caliper that supports a brake piston according to the teachingsherein. During a parking brake apply, the nut is axially moved along thecenter axis towards a bottom pocket surface of the piston pocket until afirst abutment of the nut contacts the bottom pocket surface. Aftercontact, to create a clamping force, the nut continues to be movedaxially when the spindle is rotated thus moving the brake piston and abrake pad against a brake rotor.

The present teachings also provide a brake system. The brake systemcomprises a brake piston including a piston pocket, a nut, a nut seal,and a spindle in communication with the nut. The nut seal is receivedinto a seal groove formed around the nut. The nut seal and thecorresponding seal groove in the brake piston may be any suitable shape.For example, the nut seal and the seal groove may have a circular shapeor a square shape. The nut is received into the piston pocket such thatan interference fit is created between the nut seal and the pistonpocket, an inner pocket surface, one or more projections, or acombination thereof. During a parking brake apply, or release of theparking brake apply, the spindle is rotated with a motor gear unit,which causes the nut to move axially without rotating within the pistonpocket. During release of the parking brake apply, when the nut contactsthe spindle thread stop and the motor gear unit continues to rotate thespindle, the nut can rotate within the piston pocket.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a brake caliper.

FIG. 2 is a perspective, cross-sectional view of a brake piston, a nut,and a spindle all located in a caliper bore of the brake caliper.

FIG. 3 is a perspective, exploded view of a brake piston, a nut, and aspindle.

FIG. 4 is an assembled, perspective, cross-sectional view of the brakepiston, nut, and spindle of FIG. 3.

FIG. 5 illustrates a perspective, front view of the brake piston of FIG.3.

FIG. 6 is a perspective, exploded view of a brake piston, a nut, and aspindle.

FIG. 7 is a perspective, exploded view of a brake piston, a nut, and aspindle.

DETAILED DESCRIPTION

The explanations and illustrations presented herein are intended toacquaint others skilled in the art with the teachings, its principles,and its practical application. Those skilled in the art may adapt andapply the teachings in its numerous forms, as may be best suited to therequirements of a particular use. Accordingly, the specific embodimentsof the present teachings as set forth are not intended as beingexhaustive or limiting of the teachings. The scope of the teachingsshould, therefore, be determined not with reference to the abovedescription, but should instead be determined with reference to theappended claims, along with the full scope of equivalents to which suchclaims are entitled. The disclosures of all articles and references,including patent applications and publications, are incorporated byreference for all purposes. Other combinations are also possible as willbe gleaned from the following claims, which are also hereby incorporatedby reference into this written description.

The present teachings are predicated upon providing an improved brakesystem, an improved parking brake system, or both. More particularly,the description herein relates to improved components for a brakesystem, a parking brake system, or both. The present teachings may beused with a brake system and/or a parking brake system in any vehicle.For example, the teachings herein can be used in any size car, truck,bus, train, airplane, all terrain vehicle, etc. The present teachingsmay also be used in non-vehicular applications. For example, theteachings herein may be applied to brake systems used in variousmachines, such as a lathe, a winder for paper products or cloth,amusement park rides, wind turbines, or the like.

The brake system may be any device, system, and/or assembly that maycreate a clamping force. The clamping force may be any force that issufficient to slow or prevent movement or rotation of a brake rotor;decelerates and/or prevents movement of a vehicle; or both. The clampingforce may be created during a brake apply, a parking brake apply, orboth. Exemplary brake systems include opposing brake systems (i.e., afixed caliper brake systems) and floating brake systems (i.e., afloating calipers). The brake system may generally include a brakerotor, one or more brake pads, and a brake caliper supporting one ormore brake pistons.

The brake rotor may cooperate with the components of the brake system,the components of the parking brake system, or both to create theclamping force. The brake rotor may be generally circular, and mayextend through the brake caliper; may be partially surrounded by thebrake caliper; or both. The brake rotor may rotate with a wheel and axleof a vehicle when the vehicle is in motion. The brake rotor may includean inboard side and an opposing outboard side. One or more brake padsmay be supported on the brake caliper facing the inboard side of thebrake rotor, and one or more brake pads may be supported on the brakecaliper facing the outboard side of the brake rotor. To create theclamping force during a brake apply or during a parking brake apply, thefriction material of the one or more brake pads may be moved against atleast one of the sides of the brake rotor. After the one or more brakepads are moved against the brake rotor (i.e., once the clamping force iscreated), the brake rotor may be restricted from rotating, and,accordingly, the vehicle may decelerate and/or may be restricted frommoving. After the friction material of the one or more brake pads ismoved away from the brake rotor and thus the clamping force is released,the brake rotor can once again rotate, and, accordingly, the vehicle maymove.

During a brake apply, a parking brake apply, or both the one or morebrake pads may be moved or pushed against the brake rotor to create, theclamping force. The clamping force acts to maintain a stationary vehicleat rest or acts to decelerate a moving vehicle by, converting kineticenergy of a vehicle into thermal energy. The one or more brake pads mayinclude one or more ears or projections. The one or more ears orprojections may engage a brake caliper, a support bracket, or both. Theone or more brake pads may include a friction material and a pressureplate. The one or more brake pads may be supported on the brake caliperso that the friction material faces a side of the brake rotor. Thefriction material may include one or more materials that arenon-metallic, semi-metallic, fully metallic, and/or ceramic. Thefriction material may be slotted and/or may include grooves. Thepressure plate may oppose the friction material. The one or more brakepistons and the one or more brake caliper fingers may be in selectivecontact with the pressure plate of a corresponding brake pad. Forexample, one or more brake pistons may be in selective contact with apressure plate of a brake pad located on the inboard side of the brakerotor, and one or more brake caliper fingers may be in contact with thepressure plate of a brake pad located on the outboard side of the brakerotor. During a brake apply and/or during a parking brake apply, the oneor more brake pistons and/or the one or more brake caliper fingers canbe moved so that all or an end of a corresponding brake pad is movedagainst the brake rotor to create the clamping force.

The brake caliper may function to support one or more components of thebrake system, the parking brake system, or both. The brake caliper mayprovide for the movement of one or more brake pads, or, preferably, twoor more brake pads relative to the brake rotor. The brake caliper mayinclude one or more supports configured to engage and/or support the oneor more brake pads. The brake caliper may move during a brake apply(i.e., a floating caliper), or the brake caliper may be fixed so thatthe brake caliper does not move during a brake apply (i.e., a fixedcaliper). The brake caliper may be connected to a knuckle or a supportstructure of a vehicle.

The brake caliper may include one or more caliper bores. The one or morecaliper bores may be one or more hollow regions in the brake caliperconfigured to support a corresponding brake piston. The one or morecaliper bores may be any shape. Preferably, the shape of the one or morecaliper bores corresponds to the shape of a corresponding brake piston.Preferably, the one or more caliper bores are cylindrically-shaped. Abrake piston may be supported within a respective caliper bore, andduring a brake apply or release, a parking brake apply or release, or acombination thereof may be moved along a caliper bore axis. The caliperbore axis may extend generally perpendicular to a side of the brakerotor, a pressure plate of a brake pad, or both. The caliper bore axismay be the same as, or at least collinear with a brake piston axis, anut axis, a spindle axis, or a combination thereof.

A piston seal may be located between an outer surface of the brakepiston and the caliper bore. The piston seal may be located in a sealgroove machined into the brake caliper or caliper bore. The piston sealmay support the brake piston within the caliper bore. An interferencefit may be formed between the outer surface of the brake piston and thepiston seal so that fluid leakage can be prevented. The piston seal mayfunction to restrict or prevent the brake piston from rotating. That is,the torque due to the frictional engagement between the piston seal andthe outer surface of a corresponding brake piston may be greater thanthe torque due to the frictional engagement between the nut seal and aninner pocket wall so that a brake piston does not rotate within acorresponding piston boot. Alternatively, or in addition, the torque dueto the frictional engagement between the piston seal and the outersurface of a corresponding brake piston may be greater than the torquedue to the frictional engagement between the motor gear unit, thespindle, and the nut so that the brake piston does not rotate within acorresponding piston boot. By preventing the brake piston from rotating,damage to the piston boot can thus be prevented. The piston seal, theseal groove, or both may be substantially similar to, and/or mayfunction in a manner similar to the seal and seal groove disclosed inApplicant's commonly owned US Patent Application Publication Number US2013/0081910A1 published Apr. 4, 2013, the disclosure of which is herebyincorporated by reference herein for all purposes.

The brake caliper may include one or more piston boots. The one or morepiston boots may prevent dust, moisture, and/or other debris fromentering the one or more caliper bores. The one or more piston boots mayprevent dust, moisture, and/or other debris from entering between theouter surface of the brake piston and the caliper bore. The one or morepiston boots may support a corresponding brake piston. The one or morepiston boots may be bellows. The one or more piston boots may allowaxial movement of a corresponding brake piston in and out of acorresponding caliper bore while preventing debris or moisture fromentering between the piston and the caliper bore. The one or more pistonboots may be attached to the brake caliper in the area of the caliperbores, to an outer surface of a corresponding brake piston, or both. Theone or more piston boots may be fabricated from any suitable material.Preferably, the one or more piston boots are fabricated from a flexiblematerial so that the piston boots can move, flex, bend, and/or deformwhen a corresponding brake piston is moved in and out of the caliperbore without tearing or otherwise damaging the piston boot.

The brake caliper may support one or more brake pistons. During a brakeapply, a parking brake apply, or both, the one or more brake pistons maybe moved, which may thus move the one or more brake pads against thebrake rotor to create the clamping force. Preferably, the one or morebrake pistons may be moved along a piston axis, which may be the sameas, or at least generally collinear with a corresponding caliper boreaxis, brake piston axis, nut axis, spindle axis, or a combinationthereof. The one or more brake pistons may be any shape. Preferably, theshape of the one or more brake pistons generally corresponds to theshape of a corresponding caliper bore. More preferably, each of the oneor more brake pistons may be cylindrically-shaped. Preferably, the oneor more brake pistons do not rotate about the piston axis. Preferably,the one or more brake pistons are prevented from rotating within therespective piston boots by instead providing for the corresponding nutto rotate within the piston pocket after the nut contacts the spindlethread stop and the motor gear unit continues to rotate the spindle. Theone or more brake pistons may include an outer brake piston surface. Theouter brake piston surface may be generally smooth. The outer brakepiston surface may be in sliding contact or communication with acorresponding caliper bore. The outer brake piston surface may be insliding contact and/or have an interference fit with a correspondingpiston seal. The interference fit may be sufficient to create a torquethat is greater than the torque due to the frictional engagement betweenthe nut and the piston pocket; and/or between the motor gear unit,spindle, and nut so that the brake piston is restricted from rotating.The one or more brake pistons may include an outer end surface. Theouter end surface may be selectively engaged and/or pressed against apressure plate of a brake pad (i.e., an inboard brake pad) during abrake apply, a parking brake apply, or both.

One or more brake pistons may include a piston pocket. The one or morepiston pockets may function to receive fluid, a linkage, or both. Thepiston pocket may be a cup or recess formed into an end of the brakepiston. Preferably, the piston pocket is formed into an open end of thebrake piston and extends into the brake piston towards a bottom pocketsurface. Alternatively, the piston pocket may be a core or channelextending through both ends of a brake piston. Preferably, the pistonpocket is a generally open space defined between the outer brake pistonsurface, the outer end surface, and an open end. An inner pocket wallmay cooperate with the outer bake piston surface to define a wallthickness therebetween. In some configurations, the inner pocket wallmay have an interference fit with a nut seal or fingers of a nut sealthat is sufficient to prevent the nut from rotating during a brakeapply, a parking brake apply, a brake release, and/or release of theparking brake. This may be due to the interference fit between the nutseal and/or fingers and the inner pocket wall, the projections, or bothmay be greater than a torque due to an input torque on the spindle ornut. However, during release of the parking brake, if the nut, or anabutment of the nut (i.e., “second abutment) contacts the thread stop,and the motor gear unit continues to rotate the spindle in a releasedirection, the torque due to frictional engagement between the nut sealand/or fingers and the inner pocket wall may be less than the torque ofthe motor gear unit, the spindle, and the nut. Accordingly, in thiscondition, when the input torque at the nut is greater than a torque dueto the frictional engagement of the nut seal and the piston pocket, thenut may rotate within the brake piston. However, the brake piston may berestricted from rotating because the torque due to the frictionalengagement between the outer brake piston surface and the piston sealmay be greater than the torque due to the motor gear unit, the spindle,and the nut. A bottom pocket surface may oppose the outer end surfaceand may define a wall thickness therebetween. Through the open end, eachof the one or more piston pockets may receive fluid, a linkage, or both.

In some configurations, the piston pocket may include one or moreprojections. The one or more projections may function to create aninterference fit with a nut seal. The interference fit may be sufficientto prevent the nut from rotating within the piston pocket during a brakeapply, a parking brake apply, a brake release, and/or release of theparking brake. However, during release of the parking brake, if the nutor a nut abutment contacts the thread stop, and the motor gear unitcontinues to rotate the spindle, the torque due to frictional engagementbetween the nut seal and the projections may be less than the torque ofthe motor gear unit, the spindle, and the nut. Accordingly, in thiscondition, the nut may rotate within the brake piston.

The one or more projections may form gaps between the inner pocket walland the nut seal so that air bubbles can be evacuated during fluidbleeding. In some configurations, gaps may also be formed between theinner pocket wall and the nut seal if the nut seal has a shape that isnot circular (e.g. square, irregular, or the like) of if the nut sealhas nubs, bumps, or projections and/or recesses between the nubs, bumpsor projections as shown in FIG. 7, for example.

The one or more projections may extend from the inner pocket walltowards a center piston axis. The one or more projections may extendsubstantially parallel to the brake piston axis, a nut axis, a spindleaxis, a caliper bore axis, or a combination thereof. The one or moreprojections may extend along the inner pocket wall from the bottompocket surface to the open end. Alternatively, the one or moreprojections may have a length that extends somewhere between theaforementioned ends. The one or more projections may have any suitableshape or cross section. Preferably, the one or more projections have agenerally rounded cross section; however, a square or even a triangularcross section may be suitable. The one or more projections may have ashape or cross section that is generally linear or straight, or may bearcuate shaped, zig-zag shaped, and/or irregularly shaped. The one ormore projections may be helically wrapped around the inner pocket wall;circumferentially wrapped around the inner pocket wall; irregularlywrapped around the inner pocket wall; or wrapped around the inner pocketwall in any other suitable pattern or orientation.

The one or more projections may include any suitable number ofprojections. For example, the one or more projections may include one ormore projections, two or more projections, or preferably three or moreprojections. The one or more projections may include ten or fewerprojections, eight or fewer projections, five or fewer projections, orpreferably four or fewer projections.

Each of the one or more of the projections may have an area or point onthe inner pocket wall that is created at an intersection between an edgeof a corresponding projection and the inner pocket wall. The one or moreof the projections may have any suitable angle α, β, when measured fromthe area or point between a line tangent to the inner pocket wall at thepoint and the line on the projection. Each of the one or more of theprojections may have an area at the apex or tip of the projection. Thearea may be in contact with the nut seal. Preferably, a chamfer may beadded to the area on the projection so that the nut seal is notcompromised (i.e. cut, ripped, torn, destroyed, etc.) by one or moreprojections. This may be preferred if the nut rotates within the pistonpocket in the condition when the nut contacts the spindle thread stopand the motor gear unit continues to rotate the spindle. Angle α, βbetween the point and the inner pocket wall may be the same for all ofthe projections, or the angle may differ there amongst. An angle θ mayalso be formed at the intersection of each projection wall with theinner pocket wall relative to the piston axis. The angle θ may be thesame for all projections or may vary there amongst. For example, one ormore of the angles α, β, and/or θ may be on the order of approximately 5degrees or more, 10 degrees or more, preferably 15 degrees or more 30degrees or more, or even 40 degrees or more. The angles α, β, and/or θon the order of approximately 90 degrees or less, 75 degrees or less, 60degrees or less, 45 degrees or less. In some instances, however, a pointor tangent of the one or more projections may contact the nut seal. Thismay be the case if the nut seal is fabricated from a material that isnot as complaint as a nut seal that is fabricated from a suitablecompliant material such as rubber, for example.

As was described above, to prevent the nut from rotating, a sufficienttorque or interference fit between the inner pocket wall, the one ormore projections, or both and the nut seal is desired. Therefore, asufficient ratio of a radial piston pocket dimension to a radial nutseal dimension may be preferred. The radial piston pocket dimension maybe a value measured from the center piston axis to a tip of the one ormore projections. The radial nut seal dimension may be a value measuredfrom a center of the nut seal to an outer edge thereof. Preferably, adifference between the radial piston pocket dimension and the radial nutseal dimension is less than a thickness of the nut seal to ensure asufficient interference lit.

As was previously described, to prevent the nut from rotating, it may bepreferred that the torque or frictional engagement between the nut sealand the one or more projections, the inner pocket wall, or both isgreater, than the torque due to the frictional engagement between themotor gear unit, the spindle, and the nut. If the frictional engagementbetween the motor gear unit, the spindle and the nut is greater than thefrictional engagement between the nut seal and the one or moreprojections, the inner pocket wall, or both, the nut may rotate withinthe piston pocket. This may occur if the nut contacts the spindle threadstop after the spindle and nut have been fully moved in a releasedirection. If the nut contacts the spindle thread stop and the motorgear unit continues to rotate the spindle, the nut may rotate within thepiston pocket. In this condition, the frictional engagement between thenut seal and the projections and/or the inner pocket wall may be lessthan a torque applied to the spindle by the motor gear unit so that thenut can rotate within the brake piston. Moreover, preferably, the torquedue to the frictional engagement between the outer surface of the brakepiston and the piston seal is greater than the frictional engagement dueto the input torque applied to the spindle or nut by the motor gear sothat the brake piston does not rotate. If the brake piston were torotate in a corresponding caliper bore, the piston hoot surrounding thebrake piston may tear or may be otherwise damaged.

Preferably, during release of the parking brake, the nut may be axiallymoved in a release direction a suitable distance that is sufficient tofully release the clamping force plus a sufficient additional distanceto generate a gap between a bottom pocket surface and the nut firstabutment. For example, the gap distance may be on the order ofapproximately 0.1 mm or more, approximately 0.2 mm or more,approximately 0.4 mm or more, preferably about 0.5 mm or more. The gapdistance may be on the order of approximately 1.5 mm or less,approximately 1.3 mm or less, or preferably about 1.0 mm or less.Preferably, the gap is between about 0.5 mm and 1.0 mm.

The one or more motor gear units may be any device or combination ofdevices that may generate and/or transfer a three or torque that issuitable for creating and/or releasing a clamping force. During aparking brake apply, the one or more motor gear units may generate atorque that is sufficient to move the one or more brake pistons, the oneor more brake pads, or both relative to the brake rotor to create aclamping force. During release of the parking brake, the one or more atorque applied to the spindle by the motor gear may generate a torquethat is sufficient to move the one or more brake pistons away from theone or more brake pads to release the clamping force. The one or more atorque applied to the spindle by the motor gear may generate a torquethat is sufficient to hold the one or more brake pistons against the oneor more brake pads once a clamping force has been created. The one ormore a torque applied to the spindle by the motor gear may include amotor. The motor may function to generate torque. The motor may be anysuitable motor. For example, the motor may be a DC motor, a series woundmotor, a shunt wound motor, a compound wound motor, a separately exitedmotor, a servomotor, or a permanent magnet motor. The one or more atorque applied to the spindle by the motor gear may include one or moregears that may function to transfer, increase, and/or decrease an outputforce or torque generated by the motor. At least a portion of the torqueapplied to the spindle by the motor gear may be contained within ahousing that may be integrally formed with the brake caliper; removablyattached to the brake caliper; permanently attached to the brakecaliper; or attached in any suitable way to the vehicle.

An output of a torque applied to the spindle by the motor gear may be incommunication with the one or more linkages. The one or more linkagesmay function to transfer torque applied to the spindle by the motor gearto one or more brake pistons. More specifically, the one or more,linkages may function to transfer a torque from the torque applied, tothe spindle by the motor gear into a linear or axial force to move acorresponding brake piston along the brake piston axis towards or awayfrom a corresponding brake pad. The one or more linkages may be anydevice that may perform one or more of the aforementioned functions. Forexample, the one or more linkages may be high efficiency devices, lowefficiency devices, or a combination of both. For example, the one ormore linkages may include a lead screw and nut assembly, a ball screwand ball nut assembly, or both. Each of the one or more linkages maygenerally include a spindle and a nut.

The one or more spindles may function to transfer a torque from themotor gear to a nut so that the corresponding nut, brake piston, and/orbrake pad moves against the brake rotor to create the clamping forceand/or the parking brake apply. The one or more spindles may function totransfer a torque from the motor gear to a nut so that the correspondingnut, brake piston, and/or brake pad moves away from the brake rotor torelease the clamping force and/or the parking brake apply. Each of theone or more spindles may have an input portion that is in communicationwith the motor gear, and an output portion that is in communication witha corresponding nut. The input portion may receive torque from the motorgear, or from a component or linkage in communication with the motorgear unit. For example, the input portion may receive torque from one ormore worm wheels, output shafts, etc. in communication with the motorgear unit. The input portion may include any suitable connection forconnecting the spindle with the motor gear unit or a component orlinkage of the motor gear unit. For example, the connection may includea threaded engagement, a friction engagement, an interferenceengagement, or a combination thereof. The input portion may be coupledto the motor gear unit or a component or linkage of the motor gear unitswith one or more mechanical fasteners. Preferably, the connection iskeyed (i.e., may include, teeth, gears, notches, grooves, etc.). Themotor gear units may rotate the spindle about a spindle axis, which maybe the same as, or at least collinear with a brake piston axis, acaliper bore axis, a nut axis, or a combination thereof.

The output portion of the spindle may ben communication with acorresponding nut. The output portion may include any suitableconnection for connecting with the nut. For example, the output portionmay engage a corresponding nut with a threaded engagement, a slidingengagement, an interference engagement, a permanent engagement, aremovable engagement, a keyed engagement, or a combination thereof.Preferably, the connection between the output portion of the spindle andthe nut is threaded. More preferably, the output portion is a malethreaded portion, and the nut includes a female threaded portion.

One or more of the spindles may include a spindle thread stop. Thespindle thread stop may function to prevent a spindle and acorresponding nut from binding. The spindle thread stop may preventdamage to the brake piston, the piston boot, the motor gear unit, or acombination thereof. That is, during release of the parking brake, themotor gear unit may rotate the spindle in a particular direction (e.g.,in a release direction) so that the corresponding nut axially moves awayfrom the bottom pocket surface and thus the brake pad can both move awayfrom the brake rotor to release the clamping force. Once the nut engagesthe spindle thread stop, the nut may be in its furthest position awayfrom the bottom pocket surface. Because the nut can no longer axiallymove, further rotation of the spindle may cause the nut to rotate withinthe piston pocket rather than the brake piston rotating in acorresponding caliper bore, piston boot or piston seal, or both. To doso, the frictional engagement between the nut seal and the inner pocketwall, the one or more projections, or both should be less than thetorque of the motor gear unit, the spindle and/or the nut. Preferably,the frictional engagement between the piston seal and the outer surfaceof the brake piston is greater than the frictional engagement betweenthe torque of the motor gear units and the spindle so that the pistondoes not rotate. Accordingly, risk of damaging the piston, the pistonseal, the piston boot, or the like is reduced when the nut is rotated inthe piston pocket vs. the piston rotating in the caliper bore. In someconfigurations, the motor gear units may be in communication with anelectronic control unit (ECU). The ECU may be programmed with softwareor an algorithm; and/or any other system or device may be used torestrict or prevent the nut from even contacting the spindle threadstop.

The one or more nuts may cooperate with a corresponding spindle to movea corresponding brake piston. That is, each of the one or more nuts maybe in communication with a corresponding brake piston, and may functionto transfer torque received from a corresponding spindle, motor gearunit, or both, into a linear force to move the brake piston along apiston axis. In other words, rotation of a spindle may cause thecorresponding nut to move axially along a nut axis. The nut axis may bethe same as the caliper bore axis, the brake piston axis, a spindleaxis, or a combination thereof, or may at least be collinear with atleast one of the axis. Each of the one or nuts may engage an outputportion of a corresponding spindle in any suitable manner. For example,a nut may engage a corresponding output portion with a threadedengagement, a sliding engagement, an interference engagement, apermanent engagement, a removable engagement, a keyed engagement, or acombination thereof. Preferably, the connection between the outputportion of one of the spindles and corresponding nut is threaded.

Each of the one or more nuts may include one or more nut seals. During aparking brake apply, release of the parking brake, or both, theengagement between the one or more nut seals and the inner pocket wall,the one or more projections, or both may be sufficient to at leastpartially restrict a corresponding nut from rotating. More specifically,during a parking brake apply, the torque of a frictional engagement ofthe nut seal against the inner pocket wall, the projections, or both maybe greater than the torque of the motor gear unit, the spindle, and thenut. Accordingly, during a parking brake apply, rotation of the spindlein an apply direction causes the nut to axially move along the nut axistowards the bottom pocket surface rather than rotate. Instantly afterthe parking brake is released and the clamping force is eliminated, thetorque due to the frictional engagement of the nut seal against theinner pocket wall, the projections, or both may be greater than thetorque of a frictional engagement between the spindle, and the nut.Thus, rotation of the spindle in the release direction causes the nut toaxially move along the nut axis away from the bottom pocket surfacerather than rotate. Accordingly, the motor gear unit can be protectedfrom stalling, and the brake piston can be prevented from rotating inthe caliper bore thus preventing damage to a piston boot. During releaseof the parking brake, if the nut, or an abutment of the nut contacts thespindle thread stop, and the motor gear unit continues to rotate thespindle, the torque due to frictional engagement between the nut sealand the inner pocket wall, the one or more projections, or both may beless than the torque of the motor gear unit, the spindle, and the nut sothat the nut rotates within the piston pocket. When the nut rotateswithin the piston pocket, the nut generally does not generally axiallymove.

The engagement between the one or more nut seals and the projections,the inner pocket wall, or both may also function to center or align thenut, the spindle, the linkage, or a combination thereof relative to thepiston. That is, the engagement may align and/or maintain alignmentbetween the piston axis and a spindle axis, a nut axis, or a combinationthereof.

The nut seal may be connected to the nut, a nut groove on the nut, orboth so that the nut seal does not move or rotate relative to the nut.For example, the nut seal may be over molded on the nut. For example,the nut seal may be attached to the nut or nut groove with a sufficientfastener, such as an adhesive, so that the nut seal does not moverelative to the nut or the nut groove. In some configurations, the nutseal may be installed on the nut or in the nut groove with aninterference fit so that the nut seal does not move or rotate relativeto the nut. In these types of configurations where the nut seal does notmove or rotate relative to the nut, during a release of the parkingbrake when the nut contacts the spindle thread stop, an input torqueapplied at the nut by the spindle via the motor gear unit may sufficientto overcome a torque due to the frictional engagement of the nut sealagainst the inner pocket wall and/or projections. Therefore, rotation ofthe spindle causes the engagement of the nut seal with the brake pistonto ‘slip’ so that both the nut and the nut seal rotate together with thespindle relative to the brake piston. During this condition, the brakepiston remains stationary due to the piston seal sufficiency engaging anouter surface of the brake piston and preventing the brake piston fromrotating.

In other configurations, the nut may be adapted or configured to ‘slip’and rotate relative to a nut seal that remains stationary. In this typeof configuration, during a release of the parking brake when the nutcontacts the spindle thread stop, the torque due to the frictionalengagement between the nut seal and the inner pocket wall and/orprojections is greater than the torque due to the frictional engagementbetween the nut seal and the nut or the groove in which the nut seal isreceived. Therefore, rotation of the spindle by the motor gear unit willcause only the nut to rotate with the spindle, while the nut sealremains frictionally engaged with and stationary relative to the brakepiston. During this condition, the brake piston remains stationary dueto the piston seal sufficiency engaging an outer surface of the brakepiston and preventing the brake piston from rotating.

The nut may include a flange on which or over which the nut seal isinstalled. The nut seal groove may be located on the flange. The flangemay be generally circular. The flange may be generally square. Theflange may be generally square with edges or corners that are have anarc or a radius. The arc or radius may be slightly smaller than thepiston pocket. During a manufacturing process, the flange may start offgenerally square, and an arc or radius may be added to the corners. Theflange may be generally circular with sides that are generally flat.During a manufacturing process, the flange may start off generallyround, and flats may be created or added during a subsequent processgiving the flange a generally square shape. The nut seal may be formedfrom any suitable material. For example, the nut seal may be fabricatedfrom an at least partially complaint and/or deformable material so thatthe nut seal at least partially deforms in the areas of engagement withthe one or more projections. The deformation may be temporary, orpermanent, especially over time. The one or more nut seals may have anysuitable shape. For example, the nut seal may be generally round, or maybe square. The nut seal may be generally round, but after the generallyround nut seal is installed over a nut that has a shape that is otherthan round, the nut seal may conform to that shape. For example, a roundnut seal may become generally square when installed on a nut that has agenerally share shape.

The nut seal may have a constant or uniform thickness, or the thicknessmay vary. For example, the nut seal may have one or more projectionsthat may be nubs bumps, raised portions, thickened areas, or acombination thereof. The one or more projections may be disposed atregular or irregular intervals around a perimeter or circumferencethereof. The one or more projections may engage the inner pocket wall.One or more gaps, grooves, cutouts, thinned-out areas, or a combinationthereof may be defined between the projections around the nut seal. Oneor more gaps may be formed between the inner pocket wall and the one ormore gaps defined between the projections so that air bubbles can bereleased during fluid evacuation. The projections may be disposed arounda circumference or perimeter at equal or unequal intervals. For example,the projections may be located 180 degrees or more apart, 90 degrees ormore apart, 60 degrees or more apart, 45 degrees or more apart, 30degrees or more apart. For example, the projections may be located 180degrees or less apart, 90 degrees or less apart, 60 degrees or lessapart, 45 degrees or less apart, 30 degrees or less apart. The nut sealmay include any suitable number of projections. For example, the nutseal may include one or more projections, two or more projections, threeor more projections, four or more projections, five or more projections,eight or more projections, ten or more projections. For example, the nutseal may include twenty or less projections, fifteen or lessprojections, twelve or less projections, ten or less projections.

FIG. 1 illustrates a brake caliper assembly 100. The brake caliperassembly 100 includes a brake caliper 102 and a motor gear unit 104. Thebrake caliper 102 supports an inner brake pad 106 and an outer brake pad108. Each brake pad 106, 108 comprises a friction material 110 and apressure plate 112. A brake rotor is located between the frictionmaterial 110 of both brake pads 106, 108. The brake caliper 102 includesbrake caliper fingers 114 in contact with the pressure plate 112 of theouter brake pad 108. A brake piston 118 is located, in a caliper bore166 of the brake caliper 102. The brake piston 118 is in selectivecontact with the pressure plate 112 of the inner brake pad 106.

FIG. 2 illustrates a brake piston 118 located in a caliper bore 166 ofthe brake caliper 102. A linkage 120 comprising a nut 136 and a spindle138 is located in a piston pocket 124 of the brake piston 118. The nut136 includes a groove 144 around an outer circumference thereof. A nutseal 146 is located in the groove 144. A piston seal 170 that is locatedin a seal groove 168 of the brake caliper 102 forms an interference fitwith an outer surface 172 of the brake piston 118. A piston boot 175 islocated near an end of the brake piston 118.

FIGS. 3 and 4 illustrate the brake piston 118 and the linkage 120. Thelinkage 120 comprises a nut 136 and a spindle 138. During a parkingbrake apply and/or during release of the parking brake, the brake piston118 is axially moved via the linkage 120 along a brake piston axis 134.The brake piston 118 includes an open end 122 leading into a pistonpocket 124. The piston pocket 124 extends between the open end 122 and abottom pocket wall or surface 126 (See FIGS. 4 or 5). The piston pocket124 includes an inner pocket wall 130 having one or more ribs orprojections 132. The brake piston 118 includes an outer end surface 128that, during a brake apply, a parking brake apply, or both, selectivelycontacts the pressure plate 112 of the inner brake pad 106.

During a parking brake apply and/or during release of the parking brake,the nut 136 is moved along a nut axis 140 towards or away from thebottom pocket surface 126, respectively. The nut 136 includes a firstabutment 142 that, during a parking brake apply, contacts the bottompocket surface 126. The nut 136 includes a second abutment 152 that,during release of the parking brake, is moved towards a spindle threadstop 154 on the spindle 138. Preferably, during release of the parkingbrake, the second abutment 152 does not contact the spindle thread stop154; instead, a suitable gap is realized between the second abutment 152and the spindle thread stop 154. For example, the gap between the secondabutment 152 and the spindle thread stop 154 may be on the order ofapproximately 0.5 mm to 1.0 mm. The second abutment 152 may, however,contact the spindle thread stop 154 when worn brake pads are replacedwith new brake pads, or when the brake caliper is removed from thevehicle support for service or maintenance, for example.

The nut 136 includes a groove 144 around a circumference thereof inwhich a nut seal 146 is received. The nut seal 146 is configured oradapted to engage the projections 132 extending from the inner pocketwall 130. One or more gaps 116 may be formed between the inner pocketwall 130 and the nut seal 146. The one or more gaps 116 may be formedbetween the nut seal 146 and the inner pocket wall 130 in areas adjacentthe projections 116 where the nut seal 146 does not directly contact theinner pocket wall 130. The gaps 116 may be configured or adapted toallow air that may be trapped in the brake fluid to be evacuated so thatbrake pedal “feel” can be improved.

The nut 136 includes a threaded portion 148 that threadably engagescorresponding threaded portion 150 of the spindle 138. The spindle 138has an input portion 156 for receiving torque from the motor gear unit104 (FIG. 1) so that during a parking brake apply and/or release of theparking brake, the spindle 138 is rotated in a corresponding apply orrelease direction about a spindle axis 158.

With additional reference to FIG. 5, each projection 132 extending fromthe inner pocket wall 130 includes a tip 160. When the nut 118 isreceived in the piston pocket 124, each tip 160 is configured or adaptedto engage the nut seal 146. The tip 160 may have walls 162 that areangularly oriented α, β relative to the inner pocket wall 130. Relativeto the piston axis 134, an angle θ is formed at a connection point 164between one or more projection walls 162 of the projection 132 and theinner pocket wall 130.

With reference to FIGS. 1-5, to create the clamping force during aparking brake apply, the motor gear unit 104 may rotate the spindle 138in a first direction (e.g. in an apply direction) about the spindle axis158. The torque or engagement of the nut seal 146 against the innerpocket wall 130, the projections 132, or both may be greater than thetorque generated due to friction at the thread interface of the spindle138, and the nut 136. Accordingly, rotation of the spindle 138 in thefirst direction causes the nut 136 to axially move along the nut axis140 towards the bottom pocket surface 126 rather than the nut 136rotating about the nut axis 140. After the first abutment 142 makescontact with the bottom pocket surface 126, further rotation of thespindle 128 causes the nut 136 to axially move or push the brake piston118 until the outer end surface 128 of the brake piston 118 contacts andmoves the pressure plate 112 of the inner brake pad 106 against thebrake rotor. At the same time, the fingers 114 of the brake caliper pullthe outer brake pad 108 against an opposing side of the brake rotor atwhich time clamping force begins to be developed. At this time, thefrictional contact, between the first abutment 142 and the bottom pocketsurface 126 begins to generate and increase torque that may beproportional to the increase in clamping force, and continues toincrease until the motor gear unit 104 stops rotating. The generatedtorque due to contact between the first abutment 142 and the bottompocket surface 126 quickly becomes larger than the torque generated bythe frictional contact between the nut seal 146 and the projections 132.The generated torque due to contact between the first abutment 142 andthe bottom pocket surface 126 is preferably greater than the torquegenerated due to the frictional contact between the spindle 138 and thenut 136 so that the nut 136 does not rotate with respect to the brakepiston 118 as long as clamping force is present.

With continued reference to FIGS. 1-5, to release the clamping forceand/or the parking brake apply, the motor gear unit 104 may rotate thespindle 138 in a second direction (e.g., a release direction) about thespindle axis 158. The torque or frictional engagement of the nut seal146 against the inner pocket wall 130, the projections 132, or both maybe greater than the torque of the motor gear unit 104, the spindle 138,and the nut 136. Accordingly, rotation of the spindle 138 in the releasedirection causes the nut 136 to axially move along the nut axis ratherthan rotate. Continued rotation of the spindle 138 in the releasedirection causes the frictional contact between the first abutment 142and the bottom pocket surface 126 to decrease torque in proportion tothe decrease in clamping force. Preferably, the torque due to contactbetween the first abutment 142 and the bottom pocket surface 126 remainsgreater than the torque due to the frictional contact between thespindle 138 and the nut 136 so that the nut 136 does not rotate withrespect to the brake piston 118 as long as some clamping force ispresent. Once the clamping force is fully released, the motor gear unit104 may stop rotating the spindle 138 in the release direction. Theclamping force is fully released when the first abutment 142 and thebottom pocket surface 126 are no longer in contact.

If the motor gear unit 104 continues to rotate the spindle 138 in therelease direction after the clamping force is released, such as for padreplacement, for example, and the second abutment 152 contacts thespindle thread stop 154, the input torque at the nut 136 is greater thanthe torque due to the frictional engagement between the nut seal 146 andthe inner pocket wall 130, the projections 132, or both so that the nut136 rotates in the piston pocket. The torque due to the frictionalengagement between the outer surface of the brake piston 118 and thepiston seal 170 that engages the outer surface of the brake piston 118(See FIG. 2) prevents the brake piston 118 from rotating during thiscondition. Accordingly, any further rotation of the spindle 138 in therelease direction may cause the nut 136 to rotate inside the pistonpocket 124 instead of the brake piston 118 rotating with respect to thepiston seal 170 thereby preventing possible damage to the piston seal170 and piston boot 175. Also, depending on the engagement between thenut seal 146 and the nut 136 or nut groove 144, the nut seal 146 may ormay not rotate with the nut 136 during this condition when the nut 136contacts the spindle thread stop 154. That is, if the torque due to thefrictional engagement between the nut seal 146 and the inner pocket wall130 and/or projections 132 is greater than the torque due to theengagement between the nut seal 146 and the nut 136 or the groove 144 inwhich the nut seal 146 is received, the nut 136 may “slip” relative tothe seal 146 so that rotation of the spindle 138 will cause only the nut136 to rotate with the spindle 138, while the nut seal 146 and the brakepiston 118 do not rotate. The brake piston 118 is prevented fromrotating because of the torque due to the piston seal 170 frictionallyengaging an outer surface of the brake piston 118.

Alternatively, if the torque due to the frictional engagement betweenthe nut seal 146 and the inner pocket wall 130 and/or projections 132 isless than the torque due to the engagement between the nut seal 146 andthe nut 136 or the groove 144 in which the nut seal 146 is received, thenut seal 146 may “slip” or rotate relative to the brake piston 118 sothat rotation of the spindle 138 will cause both the nut 136 and the nutseal 146 to rotate with the spindle 138, while the brake piston 118 doesnot rotate. Again, the brake piston 118 is prevented from rotatingbecause of the torque due to the piston seal 170 frictionally engagingan outer surface of the brake piston 118.

FIG. 6 illustrates a brake piston 118 and linkage 120 including a nut136 and a spindle 138. The brake piston 118 and linkage 120 of FIG. 6are substantially the same as the brake piston 118 and linkage 120 atFIGS. 3-5, except for the following noted differences. The brake piston118 includes a piston pocket 124 with an inner pocket wall 130 that issubstantially smooth and cylindrical. That is, the piston pocket 124 inFIG. 6 does not include or is free of any projections, like the onesshown in FIGS. 3-5. The nut 136 is generally square-shaped in the regionwhere the nut seal 146 is engaged in contrast to circular shape likeshown in the previous figures; however, it is understood that in thatregion, the nut 136 may be triangular-shaped, pentagonal-shaped,hexagonal-shaped, or any regular polygonal shaped. The nut seal 146shown in FIG. 6 is also generally square-shaped. However, the nut 136may have a shape that differs from the nut seal 146. For example, thenut 136 may have a certain shape, such as a cylindrical or circularshape, for example, and the nut seal 146 may have a different shape,such as a triangular or polygonal shape for example. The nut seal 146may have thicker or fatter projections that interfere with the pistonpocket 124, the inner pocket wall 130, and/or the projections 132. It isunderstood, however, that while the piston pocket 118 and the nut 136 ofFIG. 5 are slightly different than those shown in FIG. 2-5, theirfunction is substantially the same. That is, the frictional engagementbetween the nut seal 146 and piston pocket 124 of FIG. 6 prevents thenut 136 from rotating within the piston pocket 124 during creationand/or release of the parking brake, but allows the nut 136 to rotatewithin the piston pocket 124 when the second abutment 152 contacts thespindle thread stop 154 so that the brake piston 118 does not rotatewithin the piston seal 170. The square shape of the nut 136 and the nutseal 146 may restrict or prevent the nut 136 from rotating in the pistonpocket 124. In other words, when the nut 136 contacts the spindle threadstop and the spindle 138 continues to be rotated in a release direction,the square-shaped nut seal 146 may be restricted or prevented from‘slipping’ relative to the inner pocket wall 130, the projections 132,or the seal groove in the nut 136 like described above in reference toFIGS. 3-5.

FIG. 7 illustrates a brake piston 118 with a piston pocket 124 having aninner pocket wall 130 that is substantially smooth and cylindrical. Thatis, the piston pocket 124 of FIG. 7 does not include, or free of,projections 126, like the ones shown in FIGS. 3-5; it is, however,understood that such projections may be included. The nut 136 includes anut seal 146 that has one or more projections or fingers 174 that areconfigured or adapted to engage the inner pocket wall 130. Accordingly,when the linkage 120 is assembled in the brake piston 118, a gap isformed between the inner pocket wall 130 and the areas, gaps, orrecesses in the seal 146 between the projections 174 so that air bubblescan be evacuated through the gaps during fluid bleeding, for example.Operation of the parking brake apply and release may be substantiallysimilar to that described above relating to FIGS. 1-5.

Moreover, like FIGS. 3-5, if the motor gear unit 104 continues to rotatethe spindle 138 in the release direction after the clamping force isreleased, such as for pad replacement, for example, and the secondabutment 152 of the nut 136 contacts the spindle thread stop 154, theinput torque at the nut 136 becomes greater than the frictionalengagement between the nut seal 146 and/or projections or fingers 174and the inner pocket wall 130 so that the nut 136 rotates in the pistonpocket. Also, if the motor gear unit 104 continues to rotate the spindle138 in the release direction after the clamping force is released, suchas for pad replacement, for example, and the second abutment 152 of thenut 136 contacts the spindle thread stop 154, the frictional engagementbetween the nut seal 146 and/or projections or fingers 174 and the innerpocket wall 130 is preferably less than the torque due to the frictionalengagement between the outer surface of the brake piston 118 and thepiston seal 170 that engages the outer surface of the brake piston 118(See FIG. 2). Accordingly, any further rotation of the spindle 138 inthe release direction may cause the nut 136 to rotate inside the pistonpocket 124 instead of the brake piston 118 rotating with respect to thepiston seal 170 thereby preventing possible damage to the piston seal170 and piston boot 175.

During the aforementioned condition when the nut 136 contacts thespindle thread stop 154, depending on the attachment or connectionbetween the nut seal 146 and the nut 136 or nut groove in which the nutseal 146 is received, the nut seal 146 may or may not rotate with thenut 136. More specifically, if the torque due to the frictionalengagement between the nut seal 146 or fingers 174 and the inner pocketwall 130 and/or projections 132 is greater than the torque due to theconnection or engagement between the nut seal 146 and the nut 136 or thegroove 144 in which the nut seal 146 is received, the nut 136 may “slip”relative to the seal 146 so that rotation of the spindle 138 will causeonly the nut 136 to rotate with the spindle 138, while the nut seal 146and the brake piston 118 do not rotate. The brake piston 118 isrestricted or prevented from rotating due to the torque of the pistonseal engaging an outer surface of the brake piston 118.

Alternatively, if the torque due to the frictional engagement betweenthe nut seal 146 or fingers 174 and the inner pocket wall 130 and/orprojections 132 is less than the engagement between the nut seal 146 andthe nut 136 or the groove 144 in which the nut seal 146 is received, thenut seal 146 or fingers 174 may “slip” or rotate relative to the brakepiston 118 so that rotation of the spindle 138 by the motor gear unitwill cause both the nut 136 and the nut seal 146 to rotate with thespindle 138, while the brake piston 118 does not rotate. Again, thebrake piston 118 is restricted or prevented from rotating due to thetorque of the piston seal engaging an outer surface of the brake piston118.

Any numerical values recited herein include all values from the lowervalue to the upper value in increments of one unit provided that thereis a separation of at least 2 units between any lower value a any highervalue. As an example, if it is stated that the amount of a component ora value of a process variable such as, for example, temperature,pressure, time and the like is, for example, from 1 to 90, preferablyfrom 20 to 80, more preferably from 30 to 70, it is intended that valuessuch as 15 to 85, 22 to 68, 43 to 51, 30 to 32 etc. are expresslyenumerated in this specification. For values which are less than one,one unit is considered to be 0.0001, 0.001, 0.01 or 0.1 as appropriate.These are only examples of what is specifically intended and allpossible combinations of numerical values between the lowest value andthe highest value enumerated are to be considered to be expressly statedin this application in a similar manner. As can be seen, the teaching ofamounts expressed as “parts by weight” herein also contemplates the sameranges expressed in terms of percent by weight. Thus, an expression inthe Detailed Description of the Teachings of a range in terms of at “‘x’parts by weight of the resulting polymeric blend composition” alsocontemplates a teaching of ranges of same recited amount of “x” inpercent by weight of the resulting polymeric blend composition.”

Unless otherwise stated, all ranges include both endpoints and allnumbers between the endpoints. The use of “about” or “approximately” inconnection with a range applies to both ends of the range. Thus, “about20 to 30” is intended to cover “about 20 to about 30”, inclusive of atleast the specified endpoints.

The disclosures of all articles and references, including patentapplications and publications, are incorporated by reference for allpurposes. The term “consisting essentially of” to describe a combinationshall include the elements, ingredients, components or steps identified,and such other elements ingredients, components or steps that do notmaterially affect the basic and novel characteristics of thecombination. The use of the terms “comprising” or “including” todescribe combinations, of elements, ingredients, components or stepsherein also contemplates embodiments that consist essentially of theelements, ingredients, components or steps.

Plural elements, ingredients, components or steps can be provided by asingle integrated element, ingredient, component or step. Alternatively,a single integrated element, ingredient, component or step might bedivided into separate plural elements, ingredients, components or steps.The disclosure of “a” or “one” to describe an element, ingredient,component or step is not intended to foreclose additional elements,ingredients, components or steps.

It is understood that the above description is intended to beillustrative and not restrictive. Many embodiments as well as manyapplications besides the examples provided will be apparent to those ofskill in the art upon reading the above description. The scope of theteachings should, therefore, be determined not with reference to theabove description, but should instead be determined with reference tothe appended claims, along with the full scope of equivalents to whichsuch claims are entitled. The disclosures of all articles andreferences, including patent applications and publications, areincorporated by reference for all purposes. The omission in thefollowing claims of any aspect of subject matter that is disclosedherein is not a disclaimer of such subject matter, nor should it beregarded that the inventors did not consider such subject matter to bepart of the disclosed inventive subject matter.

LISTING OF REFERENCE NUMERALS

100 Brake caliper assembly

102 Brake caliper

104 Motor gear unit

106 Inner brake pad

108 Outer brake pad

110 Friction material

112 Pressure plate

114 Brake caliper fingers

116 Gaps

118 Brake Piston

120 Linkage

122 Open end

124 Piston pocket

126 Bottom pocket surface

128 Outer end surface

130 inner pocket wall

132 Projections

134 Brake piston axis

136 Nut

138 Spindle

140 Nut axis

142 First abutment

144 Seal groove

146 Nut seal

148 Threaded portion

150 Threaded portion

152 Second abutment

154 Thread stop

156 Input portion

158 Spindle axis

160 Tip

162 Projection Wall

164 Connection point

166 caliper bore

168 seal groove

170 piston seal

172 outer surface (of the brake piston 118)

174 projections (on nut seal 146)

175 piston boot

α Angle

β Angle

θ Angle

1) A brake piston comprising: a piston pocket adapted to receive a nut,the nut includes a flexible nut seal contact with the piston pocket. 2)(canceled)
 3. The brake piston of claim 1, wherein the nut seal includesone or more fingers that contact piston pocket. 4) The brake piston ofclaim 1, wherein the piston pocket includes one or more projections. 5)The brake piston of claim 1, wherein the piston pocket is cylindrical,and both the nut and the nut seal are generally square-shaped. 6)(canceled) 7) (canceled) 8) (canceled) 9) (canceled) 10) (canceled) 11)(canceled) 12) The brake piston of claim 1, wherein the piston pocketincludes one or more projections, each of the one or more projectionsextend along at least a portion of a length of the piston pocket, eachof the one or more projections partially extend from an inner pocketwall towards a center axis of the brake piston, the nut seal contactsone or more of the one or more projections. 13) The brake piston ofclaim 12, wherein an air gap is formed between the inner pocket wall andthe nut seal in areas adjacent one or more of the one or moreprojections.
 14. A disc brake system comprising the brake piston ofclaim
 1. 15) (canceled) 16) (canceled) 17) (canceled) 18) (canceled) 19)(canceled) 20) (canceled) 21) The brake piston of claim 1, wherein thenut seal is disposed around at least a portion of an outer perimeter ofthe nut. 22) The brake piston of claim 1, wherein the nut comprises agroove defined in at least a portion of an outer perimeter thereof, thenut seal is located inside the groove. 23) The brake piston of claim 1,wherein the nut seal is at least partially deformed in areas of contactwith the piston pocket. 24) The brake piston of claim 4, wherein the nutseal is at least partially deformed in areas of contact with the one ormore projections. 25) The brake piston of claim 12, wherein the nut sealis at least partially deformed in areas of contact with the one or moreprojections. 26) The brake piston of claim 1, wherein the nut sealincludes a plurality of fingers that contact the piston pocket, each ofthe fingers are spaced apart from adjacent fingers by approximately 30degrees or more around a perimeter of the nut seal. 27) The brake pistonof claim 1, wherein the nut seal includes a plurality of fingers thatcontact the piston pocket, each of the fingers are spaced apart fromadjacent fingers by approximately 60 degrees or more around a perimeterof the nut seal. 28) The brake piston of claim 1, wherein the nut sealcomprises a square cross section. 29) The brake piston of claim 28,wherein the nut has a square cross section. 30) The brake piston ofclaim 3, wherein the fingers extend radially outward from the nut seal.31) The brake piston of claim 12, wherein the piston pocket comprisesthree projections. 32) The brake piston of claim 1, wherein the nut sealcomprises a rubber material. 33) The brake piston of claim 1, whereinthe nut seal comprises a compliant material.